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Ni-based superalloys with enhanced oxidation resistance at high temperatures are crucial for next-generation gas turbine engines. A new polycrystalline Ni-based superalloy (C19) that combines improved microstructural stability with environmental resistance has been developed. Its oxidation resistance has been determined through measurements of the specific mass change and morphological evolution of the formed oxides following furnace exposures at 800 °C in air for up to 1000 hours; the results of which were benchmarked against Nimonic 105. C19 showed hybrid Type II/Type III behavior as a marginal Al2O3 former and performed similarly to established superalloys at 750 °C. The Wagner model for the transition from internal to external oxide formation predicted that C19 should form a continuous Al2O3 scale at higher temperatures. A pre-oxidation treatment at 1100 °C for 1 hour was, therefore, selected and shown to dramatically improve the oxidation resistance during subsequent exposure at 800 °C. Oxide cross-sectional analysis showed that C19 formed a continuous and protective Al2O3 scale after the pre-oxidation treatment, whereas Nimonic 105 retained discontinuous Al2O3 finger-like intrusions beneath a Cr2O3 overscale.

An assessment is made of the Wagner transition criteria for predicting the formation of a continuous Al2O3 scale in Ni-based superalloys. Predictions are compared with data from an experimental Ni-based superalloy as well as commercial superalloys for which published data are available. The methodology was generally successful in predicting the transition temperature of the commercial superalloys but underpredicted the transition temperature of the experimental superalloy by approximately 50–100 °C. The difference in the transition temperature of the experimental superalloy to form a continuous Al2O3 scale is primarily attributed to a complex oxide subscale that increased the internal volume fraction of oxide and led to reduced oxygen ingress. The sensitivity and limitations of the methodology are discussed, and recommendations are made to refine the methodology to facilitate the interpretation of oxidation behaviour in polycrystalline Ni-based superalloys.

A novel y-y'-y" dual-superlattice superalloy, with promising mechanical properties up to elevated temperatures was recently reported. The present work employs state of the art chemical and spatial characterization techniques to study the effect systematic additions of Mo, W and Fe and variations in Nb and Al contents have on the phase fraction, thermal stability, elemental partitioning and mechanical properties. Alloys were produced through arc melting followed by heat treatment. Multi-scale characterization techniques and hardness testing were employed to characterize their microstructure, thermal stability and mechanical properties. Alterations in such properties or in elemental partitioning behaviour were then explained through thermodynamic modelling. A modest addition of 1.8 at.% Mo had a strong effect on the microstructure and thermal stability: it minimized microstructural coarsening during heat treatments while not significantly decreasing the y' solvus temperature. A reduction of Nb by 0.6 at.%, strongly reduced the y" volume fraction, without affecting the y' volume fraction. The reduced precipitate fraction led to a significant reduction in alloy hardness. Fe, added to achieve better processability and reduced material cost, decreased the y' solvus temperature and caused rapid microstructural coarsening during heat treatments, without affecting alloy hardness. A reduction of Al by 0.4 at.%, reduced the y' volume fraction and the y' solvus temperature, also without affecting alloy hardness. The addition of 0.9 at.% W decreased the y' solvus temperature but increased both precipitate volume fractions. These data will be invaluable to optimize current alloy design and to inform future alloy design efforts.

The effect of Co:Ni ratio on the oxidation performance of γ-γ' alloys based on the (Ni,Co)75Al5Ti5Cr15 system (at.%) was investigated. Seven model superalloys of Co concentration 0, 9, 19, 28, 38, 47 and 56 at.% underwent isothermal oxidation in air at 800°C using both box-furnace exposure (1000 hours) and thermogravimetric analysis (100 hours). Following 1000 hours oxidation at 800°C, alloys containing 28, 38 and 47 at.% Co exhibited a flatter, more compact external scale and Cr2O3 layer as well as reduced oxygen ingress compared with alloys of lower Co content. The alloy containing 47 at.% Co exhibited two distinct morphologies.

Titanium is commonly added to nickel superalloys but has a well-documented detrimental effect on oxidation resistance. The present work constitutes the first atomistic-scale quantitative measurements of grain boundary and bulk compositions in the oxide scale of a current generation polycrystalline nickel superalloy performed through atom probe tomography. Titanium was found to be particularly detrimental to oxide scale growth through grain boundary diffusion.

Recent research has identified compositions of nickel-based superalloys with microstructures containing appreciable and comparable volume fractions of γ′ and γ″ precipitates. In this work, an alloy capable of forming such a dual-superlattice microstructure was subjected to a range of thermal exposures between 873 and 1173 K (600 and 900 ˚C) for durations of 1 to 1000 hours. The microstructures and nature of the precipitating phases were characterised using synchrotron X-ray diffraction and electron microscopy. These data have enabled the construction of a T-T-T diagram for the precipitating phases. Hardness measurements following each thermal exposure have identified the age-hardening behaviour of this alloy and allowed preliminary mechanical properties to be assessed.

Atom Probe Tomography (APT) has been utilised for an in-depth examination of the commercial polycrystalline Ni-based superalloy RR1000, assessing compositions of the primary, secondary and tertiary γ’ phases. Clear differences in the phase chemistries are noted, particularly for the tertiary γ’ to which much of the alloy strength is attributed. Trace amounts of Hf are found to segregate strongly to the primary and secondary γ’ phases, but also exhibit an extended diffusion profile across the γ-γ’ interface up to 80 nm wide. Ti, Al and Mo demonstrate similar, yet not as pronounced diffusion profiles, indicating assumed phase chemistries may not be representative of those regions adjacent to the γ-γ’ interface. Within γ’, unique element site-occupancy preferences for this alloy were identified. Finally, the grain boundary chemistry across a γ-γ interface and that of an intragranular boride were analysed, identifying the latter as a mixed M5B3 boride rich in Mo and Cr. These demonstrate further the depth of information on Ni-alloys accessible by APT, while the overall implications of results in comparison with other in-service/model alloys are also discussed.

An assessment is made of the Wagner transition criteria for predicting the formation of a continuous Al2O3 scale in Ni-based superalloys. Predictions are compared with data from an experimental Ni-based superalloy as well as commercial superalloys for which published data are available. The methodology was generally successful in predicting the transition temperature of the commercial superalloys but underpredicted the transition temperature of the experimental superalloy by approximately 50–100 °C. The difference in the transition temperature of the experimental superalloy to form a continuous Al2O3 scale is primarily attributed to a complex oxide subscale that increased the internal volume fraction of oxide and led to reduced oxygen ingress. The sensitivity and limitations of the methodology are discussed, and recommendations are made to refine the methodology to facilitate the interpretation of oxidation behaviour in polycrystalline Ni-based superalloys.